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Defense Logistics Agency Standardization Conference

Defense Logistics Agency Standardization Conference. Developing More Cost Effective Batteries. Dale Roberts Sustainment Engineering Branch Defense Supply Center Richmond Defense Logistics Agency March 2005. DLA Sustainment Engineering Reliability Initiative. Reduce Total Operating Costs.

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Defense Logistics Agency Standardization Conference

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  1. Defense Logistics Agency Standardization Conference Developing More Cost Effective Batteries Dale Roberts Sustainment Engineering Branch Defense Supply Center Richmond Defense Logistics Agency March 2005

  2. DLA Sustainment EngineeringReliability Initiative Reduce Total Operating Costs Support the War Fighter Improve Parts Availability Integrate Technology Solutions Across Services Improve Reliability

  3. Hybrid Battery Supercapacitor • Air 4.4.4.1 has prototype in testing • Technical challenges.

  4. Supercapacitor Benefits • Long life. Should outlast airframe • No maintenance • Performance over wide temperature range • No hazardous materials • Reduces battery requirements and disposals • Fast recharge

  5. AH-1 Test Table Photo provided by Bill Johnson, Air 4.4.4.1.

  6. Close-up of Bus Transfer Relay (K7) Photo provided by Bill Johnson, Air 4.4.4.1.

  7. Power Supply and 48 kW Electrical Load Provided by Bill Johnson, Air 4.4.4.1. Photo provided by Bill Johnson, Air 4.4.4.1.

  8. Test Items 2 D8565/10-1’s (blue) 1 Lead-Acid Battery (red top) 1 Supercapacitor (black top) Photo provided by Bill Johnson, Air 4.4.4.1.

  9. Data Acquisition System Photo provided by Bill Johnson, Air 4.4.4.1.

  10. (2) D8565/15-1 with No Supercapacitor(amps) Provided by Bill Johnson, Air 4.4.4.1.

  11. (2) D8565/15-1 with No Supercapacitor(voltage) Provided by Bill Johnson, Air 4.4.4.1.

  12. (2) D8565/15-1 with 40 Kj Supercapacitors(amps) Provided by Bill Johnson, Air 4.4.4.1.

  13. (2) D8565/15-1 with 40 Kj Supercapacitors(voltage) Provided by Bill Johnson, Air 4.4.4.1.

  14. Supercapacitor Availability • Supercapacitors used in testing are available for additional applications • PN 700010 (53203) NSN 6140-01-503-6137 120KJ • PN 700014 (53203) NSN 6140-01-504-4757 40KJ • DLA can support you via the Reliability Initiative, to explore development efforts involving supercapacitors. • Contact us: Sustainment Engineering Branch • Dale Roberts, Navy Team, Engineer, at 804-279-3866 • Edilia Correa, Branch Chief, at 804-279-6233

  15. NiCad to Lead-Acid Battery Conversion • Lower cost • Low maintenance • May eliminate need for charger • Better performance than older designs • Evaluate on a case-by-case basis

  16. Shelf Life Testing •Batteries often have short shelf-life •Shelf life is not always consistent •Cells may be common to batteries •Extension may be possible

  17. Separator for NiCad • NiCad performance declined • Evaluation of problem needed • Acceptable materials identified

  18. E-3 Battery Project • High cell usage • New low maintenance battery • Charger upgrade • Thermal monitoring issues • Navy experience with mixing cells • Whole battery replacement

  19. Variation in NiCad Cells Reduces Life and Performance “…. some …. cells age at different rates …. they gradually develop different charge capacities, and as the battery as a whole is charged and discharged repeatedly, these differences are accentuated - a kind of ‘survival of the fittest’ process occurs.” “.... result is …. ‘weak’ cells can be dischargedwell below the 1.1 (Volt) level, and even driven into reverse charge, before the others reach the fully discharged state. Then during recharging, the same cells tend to absorb most of the charge and overheat, while the others (…. not properly discharged) are improperly recharged and tend to suffer increased crystal growth.” Excerpts from: Electus Distribution Reference Data Sheet: NICADS.PDF USING & CHARGING NI-CAD BATTERIES (2001)

  20. NiCad Battery With Failed Cells

  21. NiCad Cell Failures

  22. NiCad Temperature Increase and Voltage Decrease in Overcharge Reference: Electus Distribution Reference Data Sheet: NICADS.PDF (1) USING & CHARGING NI-CAD BATTERIES (2001) www1.electusdistribution.com.au/notes.asp

  23. NiCad Voltage Drop at 1.1 Volts Reference: Electus Distribution Reference Data Sheet: RECHARGE.PDF (1) Title: CHOOSING A RECHARGEABLE BATTERY (2001) www1.electusdistribution.com.au/notes.asp

  24. Audits on Aviation Battery Manufacturers • Supplier changed separator and wetting agent • Changes reduced NiCad performance • Other changes may have negative impact • Goals: • Identify changes • Evaluate impact • Increase performance

  25. NiCad Deletion List Part Number Cost #/yr $/yr • M81757/9-3 $1,590.79 36 $ 47,724 • M81757/9-2 $1,547.72 20 $ 37,145 • M81757/11-3 $1,441.23 24 $ 36,031 • M81757/12-2 $2,627.79 16 $ 28,906 • M81757/7-2 $1,593.76 4 $ 0

  26. Connector Standardization MIL-PRF-8565 D8565/5-1 & /5-2 are identical, except for connector Testing connectors ECP will be generated

  27. Standardize Batteries D8565/7-1 and -2 • Battery has -1 and -2 configuration • AV-8 and AV-8B only -1 user • Standardizing to -2 requires: • ECP (engineering change proposal) • Manual changes • Upgrade is being implemented

  28. Evaluate C-5 Failed NiCad Cells • 41 failed cells evaluated • Compared with 25 cells from stock • Burns at top and water loss • Large spread in age • Root cause analysis indicates mixed cells are probable cause

  29. Crane Shelf Life Activities • Some lead-acid batteries have 6-month or less shelf-life • Evaluating options for extension: • Shelf-life data • Shelf-life testing • Environment and procedures • Alternate designs (AGM, VLRA, etc.)

  30. Battery Standardization • Reviewing part numbered batteries • Switch from FAT to QPL • Improve availability • Can improve quality

  31. Standardization Funding Issue and Resulting Exceptions Example exceptions to MIL-B-8565/10 PID. Numerous exceptions affect procurements.

  32. Examples of Exceptions NOTE: TESTING OF THE BATTERY SHALL BE IN ACCORDANCE WITH MIL-B-8565/10AS TABLE 1 WITH THE EXCEPTION OF THE FOLLOWING: E. FIGURES 5: CHANGE THE VOLTAGE PROFILE TO REVISED PROFILE (FROM MOD OF PREVIOUS CONTRACT) HAVING DISCRETE STEPS OF 19.5V, 18.5V, 13V, AND 17.0V. L. 3.6.8 CAPACITY AND ELECTRICAL PERFORMANCE: CHANGE -30C TO -26C. N. 3.6.23 PROFILE DISCHARGE AT -18C: CHANGE FOR EACH PROFILE DISCHARGE TO TWO OF THE THREE PROFILE DISCHARGES. T. 4.6.23 VIBRATION: DELETE THE TEXT OF E. AND SUBSTITUTE DURING VIBRATION, DISCHARGE THE BATTERY AT 3.5 AMPERES. U. 4.6.23 VIBRATION: IN H. DELETE 3.6.11 AND SUBSTITUTE THE 14-VOLT DISCHARGE OF 4.6.11C.

  33. Sustainment Engineering Reliability Projects DLA can support you via the Reliability Initiative, to explore development efforts involving improving reliability or technology insertion. Contact us: Sustainment Engineering Branch • Dale Roberts, Navy Team, Engineer, at Dale.Robert@dla.mil or 804-279-3866 • Edilia Correa, Branch Chief, at Edilia.Correa@dla.mil or 804-279-6233

  34. References References: John B. Timmons, PE and E. F. Koss, Operational Testing of Valve Regulated Lead Acid Batteries in Commercial Aircraft. (Concorde Battery Corporation). www.concordebattery.com/products/technical_info. Using & Charging Ni-cad Batteries, Electus Distribution Reference Data Sheet: NICADS.PDF (1) (Electus Distribution, 2001). www1.electusdistribution.com.au/notes.asp. Choosing A Rechargeable Battery, Electus Distribution Reference Data Sheet: RECHARGE.PDF (1) (Electus Distribution, 2001). www1.electusdistribution.com.au/notes.asp

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